Apparatus and method of a universal module junction box

ABSTRACT

Embodiments of the present disclosure are directed to a universal junction box for solar modules that comprises multiple sub-assemblies with a replaceable diode black and an open-IP plug sub-assembly. The universal junction box includes a first sub-assembly (junction box platform), a second sub-assembly (a replaceable diode block), and a third sub-assembly (an open sub-assembly or plug sub-assembly. If the electronics in the diode block becomes defective, a new replaceable diode block can be used to substitute into the defective diode black without having to replace the entire junction box. The open-IP plug sub-assembly provides the flexibility to couple a variety of cable sub-assembly or IMEs to the universal junction box as long as a particular selected cable sub-assembly fits with the dimension of the open-IP plug sub-assembly.

CROSS REFERENCE TO RELATED PATENT APPLICATION

This application claims priority to U.S. Provisional Application Ser.No. 62/169,758 entitled “AC Ready Module Junction Box and Method ofMaking It,” filed on 2 Jun. 2015, the disclosure of which isincorporated herein by reference in its entirety.

TECHNICAL FIELD

The present invention relates generally to solar technologies and, moreparticularly, to a solar junction box assembly for providing electronicsto solar panels.

BACKGROUND OF INFORMATION

Solar power industry has grown rapidly over the past decade, as moreenvironmentally-conscious countries are advancing renewal energy andconserving earthly resources to combat against global warming andclimate change. The urgency to scale back on carbon emissions cannot beoverstated, statement which was promulgated in the gathering of leadersaround the globe during the 2015 United Nations Climate ChangeConference, COP 21 or CMP 11, in Paris, France. The increased use ofsolar energy is a centerpiece strategy to reduce the reliance onpetroleum, along with other several solar initiatives that have beenlaunched.

Constructions of solar farms and solar projects, plus installations ofsolar panels at offices and residential homes, provide an energyefficient mechanism to absorb the sun rays as a source of energy forgenerating electricity or heating. A solar module or a photovoltaic (PV)module is a packaged and connected assembly with a matrix of solarcells. Each solar module is rated by its direct current (DC) outputpower under a set of test conditions. One industrial leading companydesigning and manufacturing solar cells and solar modules is JA Solar,www.jasolar.com.

Most solar panel installations contain an array of solar modules tosupply a greater aggregate amount of power. Like any electrical product,there is a life cycle to electronic circuitry, or sometimes there is afailure in an electrical component. When a solar module becomesdefective due to an electrical failure, one current solution is toreplace the entire module with a new solar module. Such approach can beexpensive, either singularly as a solar module or cumulatively formultiple solar modules. The current “in-module” electronics (IME) isquite fractured and difficult to implement, representing a risk forsolar cell and module companies to incorporate IME into their solarmodules. Another shortcoming of the conventional solution is that thesolar module manufactures are required to customize the outputspecification of the solar modules depending on the choice of thecoupling assembly to the solar modules.

Accordingly, it is desirable to have a solar junction box withcost-effective design for replacement of a solar module when the solarjunction box becomes defective, as well as flexibility to adapt thesolar module to various output coupling wiring specifications.

SUMMARY OF THE DISCLOSURE

Embodiments of the present disclosure are directed to a universaljunction box for solar modules that comprises multiple sub-assemblieswith a replaceable diode black and an open-IP plug sub-assembly. Theuniversal junction box includes a first sub-assembly (junction boxplatform), a second sub-assembly (a replaceable diode block), and athird sub-assembly (an open sub-assembly or plug sub-assembly. If theelectronics in the diode block become defective, a new replaceable diodeblock can be used to substitute into the defective diode black withouthaving to replace the entire junction box. The open-IP plug sub-assemblyprovides the flexibility to couple a variety of cable sub-assembly orIMEs to the universal junction box, as long as a particular selectedcable sub-assembly fits with the dimension of the open-IP plugsub-assembly.

Broadly stated, a universal solar module box mounted on a solar module,comprising a junction box platform having a base plate, a blade block,and a cover; a modular diode block coupled electrically and mechanicallyto the junction box platform via the blade block; and a plugsub-assembly having a plug block and a cable block, attachable to thejunction box platform and the modular diode block, the plug sub-assemblyproviding a protective covering to weatherize the diode block, the bladeblock, and the cable block, the cable block attachable mechanically tothe plug block, the cable block securing mechanically and electricallyto one or more output cables.

Advantageously, the claimed disclosure provides a universal junction boxdesign that has an open-IP plug sub-assembly suitable for coupling withdifferent types of cable assemblies, thereby reducing the costs and thenecessity to have different types of junction box designs specific to aparticular cable assembly specification. The claimed disclosure alsoprovides the flexibility to couple to various IME components regardlessof the functionality and size of the IME. In addition, the claimeddisclosure provides a universal junction box design that minimizes oravoids the solar module manufacturers from liability or warranty claims.

The structure and methods of the present invention are disclosed in thedetailed description below. This summary does not purport to define theinvention. The present invention contains different embodiments, whichmay be applied to various different environments. Variations upon andmodifications to these embodiments are provided for by the presentinvention, which is limited only by the claims. These and otherembodiments, features, aspects, and advantages of the invention arebetter understood with regard to the following description, appendedclaims, and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure is described with respect to specific embodiment thereof,and reference will be made to the drawing, in which:

FIG. 1A is a structural diagram illustrating a first embodiment of auniversal solar junction box in a first perspective, which is attachedto a solar panel for providing electrical connections to the solar paneland providing placement of electronics inside the universal solarjunction box, in accordance with the present invention; and FIG. 1B is astructural diagram illustrating the constituents of the universal solarjunction box in the first embodiment with three sub-assemblies (thejunction box platform, the diode block, and the open-IP plugsub-assembly), in accordance with the present invention.

FIG. 2A is a structural diagram illustrating the first embodiment of auniversal solar junction box in a second perspective, which is attachedto a solar panel for providing electrical connections to the solar paneland providing placement of electronics inside the universal solarjunction box, in accordance with the present invention; and FIG. 2B is astructural diagram illustrating the constituents of the universal solarjunction box in the second perspective with three sub-assembliesassemblies (the junction box platform, the diode block, and the open-IPplug sub-assembly), in accordance with the present invention.

FIG. 3 is a structural diagram illustrating the constituents of thejunction box platform and the diode block, in accordance with thepresent invention.

FIG. 4 is a structural diagram illustrating the constituents of theopen-IP plug sub-assembly, in accordance with the present invention.

FIG. 5 is a structural diagram illustrating the open-IP plugsub-assembly, in accordance with the present invention.

FIG. 6 is a structural diagram illustrating a combined sub-assembly ofthe junction box platform with the diode block, plug block, and cableblock, in accordance with the present invention.

FIG. 7 is a structural diagram illustrating the junction box platform(the first sub-assembly), the diode block (the second sub-assembly), andthe open-IP plug sub-assembly (the third sub-assembly), in accordancewith the present invention.

FIG. 8 is a structural diagram illustrating the junction box platform(the first sub-assembly), the diode block (the second sub-assembly), andthe open-IP plug sub-assembly (the third sub-assembly) coupled with acable sub-assembly, in accordance with the present invention.

FIG. 9A is a structural diagram illustrating a first perspective of abase plate, a diode block, and a output cable sub-assembly, inaccordance with the present invention; FIG. 9B is a structural diagramillustrating a second perspective of a base plate, a diode block, and aoutput cable sub-assembly, in accordance with the present invention; andFIG. 9C is a structural diagram illustrating a base plate, a diodeblock, and a box cover with one or more connectors, and one or morewires, in accordance with the present invention.

FIG. 10A is a structural diagram illustrating a horizontal embodiment ofone or more locking latches for affixing with the blade block, inaccordance with the present invention; and FIG. 10B is a structuraldiagram illustrating a vertical embodiment of one or more lockinglatches for affixing with the diode block, in accordance with thepresent invention.

FIG. 11A is a structural diagram illustrating the vertical locking latchembodiment for affixing with the diode block, in accordance with thepresent invention; and FIG. 11B is a structural diagram illustrating thediode block with spring connectors for receiving and affixing tovertical locking latches, in accordance with the present invention.

FIG. 12A is a structural diagram illustrating a first embodiment of theoutput cable sub-assembly with a pair of wires, in accordance with thepresent invention; and FIG. 12B is a structural diagram illustrating asecond embodiment of the output cable sub-assembly with a single wire,in accordance with the present invention.

FIG. 13A is a structural diagram illustrating a horizontal assemblyembodiment with the junction box platform, the diode block, and theopen-IP plug sub-assembly, in accordance with the present invention; andFIG. 13B is a structural diagram illustrating a vertical assemblyembodiment with the junction box platform, the diode block, and theopen-IP plug sub-assembly, in accordance with the present invention.

FIG. 14A is a structural diagram illustrating an embodiment of theuniversal solar junction box attached to a solar module frame the solarmodule in accordance with the present invention; and 14B-C areadditional structural diagrams illustrating the universal solar junctionbox in accordance with the present invention.

FIG. 15 is a structural diagram illustrating a second embodiment of theuniversal solar junction box with a DC-to-DC optimizer that can beplugged directly into the base plate without the diode, in accordancewith the present invention.

FIG. 16 is a structural diagram illustrating a third embodiment of theuniversal solar junction box with a micro-inverter that can be pluggeddirectly into the diode block, in accordance with the present invention.

FIG. 17 is a structural diagram illustrating a sample solar module witha front surface of solar cells, in accordance with the presentinvention.

FIG. 18 is a structural diagram illustrating a sample solar module witha back surface of solar cells, in accordance with the present invention.

DETAILED DESCRIPTION

A description of structural embodiments and methods of the presentinvention is provided with reference to FIGS. 1A-18. It is to beunderstood that there is no intention to limit the invention to thespecifically disclosed embodiments but that the invention may bepracticed using other features, elements, methods, and embodiments. Likeelements in various embodiments are commonly referred to with likereference numerals. In the following description, for purposes ofexplanation, numerous specific details are set forth in order to providean understanding of various embodiments of the inventive subject matter.It will be evident to those skilled in the art, however, thatembodiments of the inventive subject matter may be practiced withoutthese specific details. In general, well-known instruction instances,protocols, structures, and techniques have not been shown in detail.

The following definitions apply to the elements and steps describedherein. These terms may likewise be expanded upon.

FIG. 1A is a structural diagram illustrating a universal solar junctionbox 10, which is attached to a solar panel 100 for providing electricalconnections to the solar panel and for providing placement ofelectronics inside the universal solar junction box 10. The mainconstituents (or parts) of the universal solar junction box 10 aredepicted in FIG. 1B. The universal solar junction box 10 includes threemain sub-assemblies: a junction box platform 20 (also referred to as “afirst sub-assembly”), a diode block 30 (also referred to as “a diodesub-assembly” or “a second sub-assembly”), and a plug sub-assembly 40(also referred to as “an open-IP sub-assembly” or “an open-IP plugsub-assembly” or “a third sub-assembly”). In the first sub-assembly 10,the junction box platform 20 includes a base plate 50, a blade block 60,and a cover for base plate 70. The diode block 30 or the secondsub-assembly 30 includes one or more diodes for controlling theelectrical current supplied to the universal solar junction box 10, andthus serves to prevent short circuiting in the associated solar panel.In the third sub-assembly 40, the open-IP plug sub-assembly includes aplug block 80 and a cable block 90. A sample solar panel 100 isillustrated on FIGS. 17 and 18, with the front side 102 of the solarpanel as shown in FIG. 17 and the back side 104 of the solar panel asshown in FIG. 18.

FIG. 2A is a structural diagram illustrating the first embodiment of auniversal solar junction box in a second perspective, which is attachedto a solar panel for providing electrical connections to the solar paneland providing placement of electronics inside the universal solarjunction box. FIG. 2B is a structural diagram illustrating theconstituents of the universal solar junction box in the secondperspective with three sub-assemblies assemblies: the junction boxplatform, the diode block, and the open-IP plug sub-assembly. Theuniversal solar junction box 10 includes the junction box platform 20,which can be coupled to the diode block 30, which in turn can be coupledto the plug sub-assembly 40. In the first sub-assembly 10, the junctionbox platform 20 comprises the blade block 60, which can be inserted andcoupled (or attached) to the base plate 50 with the cover for base plate70. The diode block 30 or the second sub-assembly 30 includes one ormore diodes for controlling the electrical current supplied to theuniversal solar junction box 10, and thus serves to prevent shortcircuiting in the associated solar panel. In the third sub-assembly 40,the open-IP plug sub-assembly includes the plug block 80 and the cableblock 90.

FIG. 3 is a structural diagram illustrating the constituents of thejunction box platform 20 and the diode block 30. The blade block 60 isinserted into the base plate 50, with the cover 70, for coupling (orattaching) to the diode block 30. A combined sub-assembly of thejunction box platform 20 and the diode block 30, collectively, arereferred to as a junction box/diode block sub-assembly 72.

FIG. 4 is a structural diagram illustrating the constituents of theopen-IP plug sub-assembly 40, which includes the plug block 80 and thecable block 90. The concept of the open-IP plug sub-assembly is toprovide a greater flexibility to manufacturers that have differentspecifications for plugging into the universal solar junction box 10.The various manufactures may have a block to mount onto the universalsolar junction box 10, such as a micro inverter or solar moduleoptimization box, as well as different number of cables, such as onecable (like an AC wire), two cables, four cables, etc. A manufacture canprovide an inverter box for mounting onto the frame of the solar panel100, and connectable to the open-IP plug sub-assembly 40, for convertingdirect current (DC) to alternating current (AC) to the solar module 100.A manufacturer can provide the solar module optimization box, to mountthe open-IP plug sub-assembly 40, as a mechanism to monitor the solarmodule 100 and make adjustments to optimize the efficiency of the solarmodule 100 (or a plurality of solar modules). The concept of the open-IPplug sub-assembly is to provide a common interface (or platform) forvarious manufacturers that offers the flexibility to tailor their block(e.g., electrical/mechanical block with one or more wires) that ispluggable to the open-IP plug sub-assembly 40. Without the commoninterface, a solar module will have to provide a wide range of productlines to fit and operate with each external communication box to thesolar module. The cable block 90 has one or more open gaps for wires orcables to extend between the inside and outside of the cable block 90.In an alternate embodiment, the inverter or the solar moduleoptimization box can be integrated into the open-IP sub-assembly 40.After inserting the cable block into the plug block 80 in the open-IPBsub-assembly 40, the resulting combination of the open-IP plugsub-assembly is shown in FIG. 5.

FIG. 6 is a structural diagram illustrating a combined sub-assembly ofthe junction box platform 20 with the diode block, the plug block 80,and the cable block 90. The junction box platform 20 (or the firstsub-assembly) has assembled the base plate 50, the blade 60, and thecover 70 into one sub-assembly. The diode block 30 (or the secondsub-assembly) is not shown in this figure. On the other end, the open-IPsub-assembly (or the third sub-assembly) is illustrated with the plugblock 80 and the cable block 90.

FIG. 7 is a structural diagram illustrating the junction box platform 20(the first sub-assembly), the diode block (the second sub-assembly), andthe open-IP plug sub-assembly 40 (the third sub-assembly). The junctionbox platform 20 has been assembled into one sub-assembly in this figureto include the base plate 50, the blade 60, and the cover 70. Theopen-IP sub-assembly 40 has been assembled into one sub-assembly in thisfigure to include the plug block 80 and the cable block 90. The diodeblock 30 (“the replaceable diode block”), which is a modular unit thatcan be removed and singularly replace the defective diode block 30,rather than the entire solar junction box 10, is shown to be placedbetween the junction box platform 20 and the open-IP sub-assembly 40.

FIG. 8 is a structural diagram illustrating the junction box platform 20(the first sub-assembly), the diode block 30 (the second sub-assembly),and the open-IP plug sub-assembly 40 (the third sub-assembly) coupledwith a cable sub-assembly 92. The cable sub-assembly 92 plugs into thecable block 80 and the plug block 90 in the open-IP plug sub-assembly40. In one embodiment, the cable sub-assembly 92 has a pair of cablesthat serve the solar module output with positive polarity and negativepolarity. The cables or wires in the cable sub-assembly 92 are alsoreplaceable and can be removed or unplugged from the open-IPsub-assembly for replacement, servicing, or testing of functions. Afterservicing or testing, the existing cable sub-assembly 92, if the part isoperational, a new cable sub-assembly 92, is plugged back in to thecable sub-assembly 92. In another embodiment, the cables on the cablesub-assembly 92 can be one or more DC cables or AC cables that operateas one or more micro-converters used to convert DC power to AC power.The cable sub-assembly 92 can be constructed from various embodiments totailor to a specific device that will be plugged into the universalsolar junction box 10.

FIG. 9A is a structural diagram illustrating a first perspective of thebase plate 50, the replaceable diode block 30, and an output cablesub-assembly 94. In one embodiment, the base plate 50 is attached to thebackside of the solar module 100. As an example of attachment, the baseplate 50 is glued to the backside of the solar module 100. Otherattaching methods of the base plate 50 to the solar module 100 arewithout departing from the spirits of the present disclosure. The outputcable sub-assembly 94 includes the open-IP sub-assembly and one or morecables 92. FIG. 9B shows another perspective of the same components ofthe base plate 50, the replaceable diode block 30, and the output cablesub-assembly 94. FIG. 9C is a structural diagram illustrating the baseplate 50 with a cage 46, the replaceable diode block 30, and the outputcable sub-assembly 94 with a box cover 96. The box cover 96 can beplaced over the cage 46 for assembling the base plate 50, thereplaceable diode block 30, and the output cable sub-assembly 94.

FIG. 10A is a structural diagram illustrating a horizontal embodiment ofone or more locking latches 42 a and 42 b for affixing with the bladeblock 60. The base plate 50 is attached (such as glued) to the framemodule and affixed (such as screwed) to the module frame 100 foradditional strength to allow larger IME to be plugged. For example, theIME includes electronics such as inverters, DC-DC optimizers, etc.Optionally, an aluminum bar can also be inserted as part of the cage 46for grounding. The blade block 60 extends through one or more slots 64a, 64 b, 64 c, and 64 d in the base plate 50 one or more electricalconducting blades 32 a and 32 b. Each of the electrical conductingblades 32 a and 32 b is inserted through a corresponding one of theslots 64 a and 64 b. Alternatively, a vertical embodiment with one ormore locking latches for affixing with a vertical blade block 66 isillustrated in FIG. 10B.

FIG. 11A is a structural diagram illustrating the vertical locking latchembodiment for affixing with the replaceable diode block 30. Thereplaceable diode block 30 includes one or more blade connectors 32 aand 32 b for plugging into the base plate 50. When the diode block 30becomes defective, it can be easily unplugged from the based plate 40and replaced with a new diode block 30. The modularity of thereplaceable diode block 30 mitigates the expensive and cumbersomeapproach of having to replace the entire sole module when one of thediodes, which is sealed to a solar junction box, becomes defective. Thereliability and life cycle of a diode can be a weak point in the solarmodule. If one of the diodes in a traditional sealed diode block isshort circuited, the solution is relatively expensive in having toreplace the entire solar module instead of just a diode block.

FIG. 11B is a structural diagram illustrating the replaceable diodeblock 30 with spring connectors 36 a and 36 b for receiving and affixingto vertical locking latches 66. In this embodiment, the replaceablediode block 30 includes three diodes 34 a, 34 b, and 34 c, that arepre-assembled in one block, as well as spring connectors 36 a and 36 b,electrical conducting blade connectors 32 a and 32 b, and on or morewires 38. The spring connector 36 a is electrically connected to thediode 34 a via a wire, which is electrically connected to the electricalconducting blade connection 32 a via a wire 38 a, which is electricallyconnected to the diode 34 a via a wire 38 b, which is electricallyconnected to the electrically conducting blade connector 32 via a wire38 c, which is electrically connected to the diode 34 c via a wire 38 d,and which is electrically connected to the spring connector 36 b via awire 38 e. Each of the diodes 34 a, 34 b, and 34 c produce heat whenactive. The replaceable diode block 30 can include an optional heatdissipating silicon 31 a within a cavity 31 b of the replaceable diodeblock 30, thereby reducing, or preventing overheating caused to one ofthe diodes. The heat dissipating silicon 31 a can be filled throughoutthe entire cavity 31 b of the replaceable diode block 30, or surroundingthe exterior areas of the diodes 34 a, 34 b, and 34 c. Other types ofheat dissipating materials that are suitable to operate with diodes canalso be used.

FIG. 12A is a structural diagram illustrating a first embodiment of theoutput cable sub-assembly 94 with a cover 96 for attaching to a pair ofwires 92 a and 92 b. The cover 96 in the output cable sub-assembly 94can be used to mechanically and electrically coupled to operate with anytypes of IMEs to service their customers. One benefit from this type ofdesign is the allocation of warranties. While a first company, such asJA Solar, provides a solar module, including a junction box, and theassociated warranty for the solar module, the second company whoprovides an IME for coupling to the cover 96 of the output cablesub-assembly 94 would provide the warranty for that portion of theelectronics and part. This effectively reduces the warranty exposure andliability of the solar module company. In an alternative embodiment,FIG. 12B is a structural diagram illustrating a second embodiment of theoutput cable sub-assembly with a single wire 92 c that is mechanicallyand electrically coupled to the cover of the output 98 cablesub-assembly 94.

FIG. 13A is a structural diagram illustrating a horizontal assemblyembodiment with the junction box platform 20, the diode block 30, andthe output cable sub-assembly 94 (or open-IP plug sub-assembly 40 withthe pair of cables 92 a and 92 b). In this horizontal assemblyembodiment, the junction box platform 20 includes the horizontal bladeblock 60, which has one or more horizontal blades that extendhorizontally to the replaceable diode block 30. The open-IP plugsub-assembly 40 also has a horizontal construction for coupling to thereplaceable diode block 30. FIG. 13B is a structural diagramillustrating a vertical assembly embodiment with the junction boxplatform 20, the diode block 30, and the output cable sub-assembly 95(or the open-IP plug sub-assembly 40 and the pair of cables 92 a and 92b). In this vertical assembly embodiment, the junction box platform 20includes the vertical blade block 66, which has one or more verticalblades that extend vertical to the replaceable diode block 30. Theopen-IP plug sub-assembly 40 also has a vertical construction forcoupling to the replaceable diode block 30.

FIG. 14A is a structural diagram illustrating an embodiment of theuniversal solar junction box 10 attached to a solar module frame 106 ofthe solar module 100. Additional views of the universal solar junctionbox 10 are shown in FIGS. 14B-C. FIG. 15 is a structural diagramillustrating a second embodiment of the universal solar junction box 10with a DC-to-DC optimizer 39 that can be plugged directly into the baseplate 50 without the diode. Other alternative interface boxes can alsobe used in place of the DC-to-DC optimizer 39 or the replaceable diodeblock 30 for mechanically coupling between the junction box platform 20and the open-IP sub-assembly. FIG. 16 is a structural diagramillustrating a third embodiment of the universal solar junction box 10with a micro-inverter 110 that can be plugged directly into thereplaceable diode block 30 and coupling between the junction boxplatform 20 and the open-IP sub-assembly.

Certain embodiments are described herein as including logic or a numberof components, modules, or mechanisms. Modules may constitute eithersoftware modules (e.g., code and/or instructions embodied on amachine-readable medium or in a transmission signal) or hardware modules(or hardware units, or hardware circuits, depending on engineeringimplementation). A hardware module is a tangible unit capable ofperforming certain operations and may be configured or arranged in acertain manner. In example embodiments, one or more electronics (orcomputer systems) or one or more hardware modules of a computer systemmay be configured by software an application or application portion) asa hardware module that operates to perform certain operations asdescribed herein.

In various embodiments, a hardware module may be implementedmechanically or electronically. For example, a hardware module maycomprise dedicated circuitry or logic that is permanently configured(e.g., as a special-purpose processor, such as a field programmable gatearray (FPGA) or an application-specific integrated circuit (ASIC)) toperform certain operations. A hardware module may also compriseprogrammable logic or circuitry (e.g., as encompassed within ageneral-purpose processor 712 or other programmable processor) that istemporarily configured by software to perform certain operations. Itwill be appreciated that the decision to implement a hardware modulemechanically, in dedicated and permanently, configured circuitry, or intemporarily configured circuitry (e.g., configured by software) may bedriven by cost and time considerations.

Accordingly, the term “hardware module” should be understood toencompass a tangible entity, be that an entity that is physicallyconstructed, permanently configured (e.g., hardwired) or temporarilyconfigured (e.g., programmed) to operate in a certain manner and/or toperform certain operations described herein. Considering embodiments inwhich hardware modules are temporarily configured (e.g., programmed),each of the hardware modules need not be configured or instantiated atany one instance in time. For example, where the hardware modulescomprise a general-purpose processor configured to using software, thegeneral-purpose processor may be configured as respective differenthardware modules at different times. Software may accordingly configurea processor, for example, to constitute a particular hardware module atone instance of time and to constitute a different hardware module at adifferent instance of time.

Modules can provide information to, and receive information from, othermodules. For example, the described modules may be regarded as beingcommunicatively coupled. Where multiples of such hardware modules existcontemporaneously, communications may be achieved through signaltransmission (e.g., over appropriate circuits and buses) that connectthe modules. In the embodiments where multiple modules are configured orinstantiated at different times, communications between such modules maybe achieved. For example, communications may occur through the storageand retrieval of information in memory structures where the multiplemodules have access. For example, one module may perform an operationand store the output of that operation in a memory device to which it iscommunicatively coupled. A further module may, at a later time, accessthe memory device to retrieve and process the stored output. Modules mayalso initiate communications with input or output devices, and canoperate on a resource (e.g., a collection of information).

The various operations of example methods described herein may beperformed, at least partially, by one or more processors that aretemporarily configured (e.g., by software, code, and/or instructionsstored in a machine-readable medium) or permanently configured toperform the relevant operations. Whether temporarily or permanentlyconfigured, such processors may constitute processor-implemented (orcomputer-implemented) modules that operate to perform one or moreoperations or functions. The modules referred to herein may, in someexample embodiments, comprise processor-implemented (orcomputer-implemented) modules.

Plural instances may be provided for components, operations, orstructures described herein as a single instance. Finally, boundariesbetween various components, operations, and data stores are somewhatarbitrary, and particular operations are illustrated in the context ofspecific illustrative configurations. Other allocations of functionalityare envisioned and may fall within the scope of the embodiment(s). Ingeneral, structures and functionality presented as separate componentsin the exemplary configurations may be implemented as a combinedstructure or component. Similarly, structures and functionalitypresented as a single component may be implemented as separatecomponents. These and other variations, modifications, additions, andimprovements fall within the scope of the embodiment(s).

As used herein any reference to “one embodiment” or “an embodiment”means that a particular element, feature, structure, or characteristicdescribed in connection with the embodiment is included in at least oneembodiment. The appearances of the phrase “in one embodiment” in variousplaces in the specification are not necessarily all referring to thesame embodiment.

Some embodiments may be described using the expression “coupled” and“connected” along with their derivatives. It should be understood thatthese terms are not intended as synonyms for each other. For example,some embodiments may be described using the term “connected” to indicatethat two or more elements are in direct physical or electrical contactwith each other. In another example, some embodiments may be describedusing the term “coupled” to indicate that two or more elements are indirect physical or electrical contact. The term “coupled,” however, mayalso mean that two or more elements are not in direct contact with eachother, but yet still co-operate or interact with each other. Theembodiments are not limited in this context.

As used herein, the terms “comprises,” “comprising,” “includes,”“including,” “has,” “having” or any other variation thereof, areintended to cover a non-exclusive inclusion. For example, a process,method, article, or apparatus that comprises a list of elements is notnecessarily limited to only those elements but may include otherelements not expressly listed or inherent to such process, method,article, or apparatus. Further, unless expressly stated to the contrary,“or” refers to an inclusive or and not to an exclusive or. For example,a condition A or B is satisfied by any one of the following: A is true(or present) and B is false (or not present), A is false (or notpresent) and B is true (or present), and both A and B are true (orpresent).

The terms “a” or “an,” as used herein, are defined as one or more thanone. The term “plurality,” as used herein, is defined as two or morethan two. The term “another,” as used herein, is defined as at least asecond or more.

The foregoing description, for purpose of explanation, has beendescribed with reference to specific embodiments. However, theillustrative discussions above are not intended to be exhaustive or tolimit the embodiments to the precise forms disclosed. Many modificationsand variations are possible in view of the above teachings. Theembodiments were chosen and described in order to best explain theprinciples and its practical applications, to thereby enable othersskilled in the art to best utilize the embodiments and variousembodiments with various modifications as are suited to the particularuse contemplated.

What is claimed and desired to be secured by Letters Patent of theUnited States is:
 1. A universal solar module box mounted on a solarmodule, comprising: a junction box platform having a base plate, a bladeblock, and a cover; a modular diode block coupled electrically andmechanically to the junction box platform via the blade block; and aplug sub-assembly having a plug block and a cable block, attachable tothe junction box platform and the modular diode block, the plugsub-assembly providing a protective covering to weatherize the diodeblock, the blade block, and the cable block, the cable block attachablemechanically to the plug block, the cable block securing mechanicallyand electrically to one or more output cables.
 2. The universal solarmodule box of claim 1, wherein the modular diode block is a replaceablecomponent when one of the diodes in the modular diode block fails. 3.The universal apparatus of claim 1, wherein the modulator diode blockcomprises three diodes for protecting a plurality solar cells on thesolar module.
 4. The universal apparatus of claim 1, wherein themodulator diode block comprises at least one diode.
 5. The apparatus ofclaim 1, wherein the plug sub-assembly is coupled to a pair of cables.6. The universal apparatus of claim 1, wherein the plug sub-assembly iscoupled to a single cable.
 7. The universal solar module box of claim 1,wherein the junction box platform having a cage that is mechanicallyattached to the solar module frame and the base plate for distributingthe physical load to the frame from the base plate.
 8. The universalsolar module box of claim 1, wherein the plug sub-assembly comprises oneor more micro-inverters.
 9. The universal solar module box of claim 1,wherein the plug sub-assembly comprises one or more micro-inverters andelectronics.
 10. The universal solar module box of claim 1, wherein thesolar module has a module frame, further comprising a cage metallicframe mechanically attached to the module frame and the base plate,thereby distributing the load and weight to the module frame from thebase plate.
 11. A universal solar module box mounted on a solar module,comprising: a junction box platform having a base plate, a blade block,and a cover, the base plate having a structure for attaching to one of aplurality of plug sub-assemblies dependent on the selection of aparticular plug sub-assembly, the selected plug sub-assembly includingelectronics that optimize or invert a solar module output power for thesolar module; and a modular diode block coupled electrically andmechanically to the junction box platform via the blade block.
 12. Theuniversal solar module box of claim 11, wherein the particular plugsub-assembly comprises an open-IP plug sub-assembly having a plug blockand a cable block, attachable to the junction box platform and themodular diode block, the plug sub-assembly providing a protectivecovering to weatherize the diode block, the blade block, and the cableblock, the cable block attachable mechanically to the plug block, thecable block securing mechanically and electrically to one or more outputcables.
 13. A universal solar module box mounted on a solar module,comprising: a junction box platform having a base plate, a blade block,a cover, and a cage; a modular diode block coupled electrically andmechanically to the junction box platform via the blade block; and aplug sub-assembly having a plug block and a cable block, attachable tothe junction box platform and the modular diode block, the plugsub-assembly providing a protective covering to weatherize the diodeblock, the blade block, and the cable block, the cable block attachablemechanically to the plug block, the cable block securing mechanicallyand electrically to one or more output cables.